Maintenance schedule

Sauer compressor

WP65L

WP65L_WA_01, 2009-01
Titel_65L_1.fm

Titel_65L_1.fm

Edited by: ZINDEL AG – Technical Documentation, www.zindel.de

1

Maintenance

1. Maintenance
1.1 J.P. SAUER & SOHN maintenance service
J.P. SAUER & SOHN customer service offers various mainte-
nance services: inspections, maintenance, major overhauls, re-
conditioned compressors and service contracts.

1.2 Safety during maintenance

Before mainte- 1. Interrupt power supply to the compressor.
nance work 2. Fit 'Warning: maintenance work' warning sign to power supp-
ly.
3. Shut off the compressor and secure to prevent restarting.

Danger!
Risk of injury due to incorrect operation!
Only authorised personnel are permitted to service and adjust
the Sauer compressor!

Danger!
Risk of injury from hot surfaces!
Let compressor cool down after turning OFF.

Danger!
Risk of injury due to pressurised components!
Before undertaking any maintenance work, use pressure gauge
to ensure that there is no more pressure in the compressor.

Danger!
Danger! High voltage!
– Never assume that a circuit is de-energised – always check
for your own safety!
– The mains isolator remains energised, even when it is turned
OFF.
– Components being worked on should only be energised if this
is explicitly specified.
I_WA008_3.fm

3
 Danger!
Danger of death if there are no safety devices or no isolating pro-
tection devices!
After undertaking servicing work, always refit all safety devices
and isolating protection devices. This also applies to electrical
protection devices.

1.3 Maintenance schedule

Danger!
Whenever undertaking maintenance work, observe section 1.4,
'Table of tightening torques', for particular bolts.
Note!
The maintenance intervals specified in the maintenance sche-
dule must be observed. Shortening the maintenance intervals is
of no advantage with regard to the operating performance or ser-
vice life of the Sauer compressor.
Note!
After the final maintenance routine, the maintenance schedule
starts from the beginning.

Use of the mainte- • Use the maintenance schedule as a master template or copy
nance schedule the relevant page from the digital document and save it as a
separate file under a suitable name. Use the maintenance
schedule as a guide and for verification.
• Regularly check the maintenance schedule to see which main-
tenance intervals are due depending upon the number of ope-
rating hours. The intervals are shown in the table's column
headers.
• Check the column for each maintenance interval to see which
maintenance work is to be carried out at the end of the main-
tenance interval. The required tasks are indicated by checkbo-
xes. A description and the section number of the tasks are
shown in the first column.
• Carry out all maintenance tasks for a maintenance interval
and tick the appropriate check boxes of the maintenance
schedule. Then enter hours of operation, date and signature.
• When beginning a new maintenance schedule:
– enter: maintenance schedule number, date and hours of
operation, main specifications and date of commissioning;
– mark with a cross: beginning of this maintenance schedu-
le following commissioning or following the last mainte-
nance routine.
I_WA008_3.fm

4
 Maintenance

Maintenance Schedule No. Compressor type: WP65L

Beginning of this maintenance sche- Type series
2L
dule:
❑ after commissioning Compressor number:

❑ after last maintenance routine Factory no.:

Date: Year of construction:

Hours of operation: Date of commissioning:

Interval
[hours of operation]

At least annually
commissioning

last major overhaul

at < 1000 h
50 h after

50 h after

or repair

2000 h
1000 h

3000 h

4000 h
Maintenance task

069146

069147

069146

069148
Maintenance set item no.

Check screwed connections, section 1.5 ❑ ❑

Replace air filter cartridge, section 1.6 ❑ ❑ ❑ ❑ ❑
Carry out oil change, section 1.7 ❑ ❑ ❑ ❑ ❑ ❑ ❑
Check 1st-stage valves, section 1.8 ❑ ❑
Check 2nd-stage valves, section 1.8 ❑ ❑
Replace 1st-stage valves, section 1.9 ❑ ❑
Replace 2nd-stage valves, section 1.9 ❑ ❑
Replace 1st-stage piston rings, gudgeon pins and ❑
gudgeon pin bearings, section 1
1.10
Replace 2nd-stage piston rings, gudgeon pins and ❑
gudgeon pin
bearings, section 1.10
Check piston and cylinder, section 1.11 ❑
Renew flexible gear rim, section 1.12 ❑
Check condensate separator, section 1.13 ❑
Overhaul drain valves ❑
(as per order), section 1.14
Hours of operation

Date

Signature
(initials)
I_WA008_3.fm

5
1.4 Table of torques

Bolt(s) Torque

Flywheel bolt 175 Nm

Cylinder head nuts, 1st stage 42 Nm

Cylinder head nuts, 2nd stage 75 Nm

1.5 Checking screwed connections

Check all unions and screwed connections for tightness and re-
tighten if necessary. This relates to:
– cooler and air lines;
– unions on pipe and hose lines;
– cylinder heads;
– cylinders;
– electric motor;
– measuring and switching devices;
– bearing; and
– accessories and equipment parts.

1.6 Replacing air filter cartridge

Wing nut

1. Unscrew wing nut and take air filter cap off.

2. Remove used air filter cartridge.
3. Insert new cartridge into air filter.
4. Place cap back on and screw on wing nut.
I_WA008_3.fm

6
 Maintenance

1.7 Changing oil

Note!

Use oil according to the lubricant table (see Sauer oil recom-
mendation or operating manual section 10).

Oil filler cap

Dipstick

Oil drain plug

1. Run compressor for approx. 5 minutes until operating tempe-

rature is reached.
2. Place drip tray (of a capacity sufficient to hold the complete
oil filling quantity, 5.2 l) below the oil drain plug.
3. Unscrew oil filler cap (red), unscrew oil drain plug and pull out
dipstick.
4. Wait until all oil is drained.
5. Screw on oil drain plug with a new ring.
6. Top up oil and check level with the dipstick.
✓ The level should be between the upper and lower marks on
the dipstick.
I_WA008_3.fm

7. Put dipstick back in and screw oil filler cap back on.

7
1.8 Checking valves
Removing valves 1. Remove hose line of crankcase vent from 1st-stage cylinder
head.
2. Remove cylinder head nuts and remove cylinder heads.
3. Carefully remove valves.

Checking valves 4. Check valves externally for:

(1st- and 2nd-sta- damage,
ge) oiling,
carbonisation,
corrosion and
moisture.
Replace damaged, severely carbonised or corroded valves.
Determine cause.
5. Clean all sealing surfaces.

Note!
Refit all valves with new gaskets and rings only. Only use original
Sauer spare parts.
Fitting other gaskets may result in leaks and could cause sub-
stantial damage to the compressor.

Installing valves
Low tolerance gasket

Cylinder head gasket

I_WA008_3.fm

8
 Maintenance

Note!
Never reuse or turn over and reuse an old low tolerance gasket.
This can lead to leaks in a short time.

6. Insert 1st-stage valve with new original Sauer gaskets.

7. Screw on cylinder head nuts tightly.
Observe tightening torque (see section 1.4).

Cylinder head
gasket

O-ring

8. Insert new O-ring into groove under valve in 2nd-stage cylin-

der.
9. Insert new original Sauer cylinder head gasket between valve
and cylinder head.
10. Attach 2nd-stage cylinder head. Fasten all screwed connec-
tions hand-tight.
11. Screw on cylinder head nuts tightly. Observe tightening
torque (see section 1.4).
12. Screw unions and hose line to the cylinder heads.

Note!
Valves are those parts of a reciprocating compressor that are
subject to the most stress. In order to achieve the guaranteed
maintenance routines, these valves are high-quality precision
parts which have been co-ordinated especially to the individual
compression stages and checked carefully for proper functioning
before delivery.

1.9 Replacing valves

Remove and install valves as described in section 1.9, 'Checking
I_WA008_3.fm

valves'. Replace complete valve.

9
 Note!
Valves whose service life has expired must be replaced and dis-
posed of.
Due to material fatigue, we recommend that used valves not be
repaired.

1.10 Replacing piston rings, gudgeon pins and gudgeon pin bea-
rings
1. Remove cylinder heads and valves as described in section
1.8, 'Checking valves'. Carefully clean all sealing surfaces.
2. Remove cylinder head nuts.
3. Remove cylinders. Grab and hold the piston before you have
completely removed the cylinder.

Note!
If you do not hold the piston while you remove the cylinder, it will
collide with the crankcase.

4. Remove the safety rings of the piston pins, press the piston
pins out and remove the pistons.
5. Clean piston and replace all piston rings. Make sure they are
in the correct positions: piston rings with asymmetric cross
sections are marked on one of the surfaces with 'TOP'. The
marked face must be at the top when the piston ring is in-
stalled. See illustration.

Note!
Replace all piston rings with new ones! The following damage
may occur on removal of the piston rings:
• the edges of the piston rings may be damaged on the wearing
edges in the cylinder;
• fine cracks which can lead to material fracture may appear if
the piston rings are bent up repeatedly.
I_WA008_3.fm

10
 Maintenance

1st stage 2nd stage

TOP
TOP
TOP
TOP

6. Press the gudgeon pin bearing out from the connecting rod
eye using suitable tools and renew.
7. Install piston with the new, halfway-inserted gudgeon pin in
the cylinder.

Note!
The piston ring gap must be staggered.

8. Insert new original Sauer cylinder base gasket.

9. Assemble piston together with cylinder by pressing the gud-
geon pin in at the connecting rod. Observe tightening torque
(see section 1.4).
10. Insert circlips precisely into grooves.
11. Install valves and cylinder heads as described in section 1.8,
'Checking valves'.

1.11 Checking pistons and cylinders

1. Remove cylinder heads and valves as described in section
1.9, 'Checking valves'.
2. Remove cylinders and pistons as described in section 1.10,
'Replacing piston rings'.
3. Check cylinders and pistons for scoring and heavy wear and
tear marks. Replace relevant parts.
4. Measure cylinders and replace if the following wear limits are
exceeded:

Cylinders Wear limit for diameter

1st stage 136.15 mm

I_WA008_3.fm

2nd stage 60.10 mm

11
 5. Install cylinders and pistons as described in section 1.10, 'Re-
placing piston rings'.
6. Install valves and cylinder heads as described in section 1.9,
'Checking valves'.

1.12 Renewing flexible gear rim

Note!
This applies to Sauer compressors with electric motors.

Renewing flexible 1. Support compressor under the coupling bell housing.

gear rim 2. Remove the electric motor mounting screws.
3. Carefully lift the electric motor using the lifting eyes (see ope-
rating manual section 5.1, 'Transport').
4. Carefully pull the electric motor away from the compressor.
5. Replace flexible gear rim.
6. Carefully slide electric motor against the compressor and
tighten the motor mounting screws.
7. Remove support from under the coupling bell housing.

Flexible gear rim

Compressor Motor

8. Reinstall separated connecting lines and pipes.

I_WA008_3.fm

12
 Maintenance

1.13 Cleaning condensate separators

Strainer Screw plug

1. Remove screw plug.

2. Pull out strainer.
3. Check separator for obstructions.
4. Insert new strainer.
5. Screw in plug.
I_WA008_3.fm

13
1.14 Overhauling water drain valves
Hexagon nut

1. Unscrew hexagon nut.

2. Carefully lift up plastic threaded part with the screwdriver.
3. Remove coil from armature.
4. Unscrew the four Allen screws.
5. Remove upper section of valve.
6. Replace following parts:
conical spring, diaphragm and two O-rings.
7. In case of severe soiling: clean nozzle.
8. Position upper section of valve.
9. Tighten the four Allen screws.
10. Place the coil on the armature.

Note!
The coil and the armature must always be dry.

11. Correctly position the plastic threaded part and press onto the
armature.
12. Carefully position hexagon nut by hand and screw on.
13. Lightly tighten hexagon nut using a spanner.
I_WA008_3.fm

14